Emerson World Class 3000 O2 Analyzer User manual

Instruction Manual

IB-106-300NH Rev. 4.2

July 2002

http://www.processanalytic.com

World Class 3000

Oxygen Analyzer

with IFT 3000 Intelligent

Field Transmitter

Emerson Process Management

Rosemount Analytical Inc.

Process Analytic Division

1201 N. Main St.

Orrville, OH 44667-0901

T (330) 682-9010

F (330) 684-4434

e-mail: gas.csc@EmersonProcess.com

http://www.processanalytic.com

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical designs, manufactures and tests its products to meet many national and

international standards. Because these instruments are sophisticated technical products, you

MUST properly install, use, and maintain them to ensure they continue to operate within their

normal specifications. The following instructions MUST be adhered to and integrated into your

safety program when installing, using, and maintaining Rosemount Analytical products. Failure to

follow the proper instructions may cause any one of the following situations to occur: Loss of life;

personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Rosemount Analytical repre-

sentative for clarification.

• Follow all warnings, cautions, and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation, and mainte-

nance of the product.

• Install your equipment as specified in the Installation Instructions of the appropriate In-

struction Manual and per applicable local and national codes. Connect all products to the

proper electrical and pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update, program,

and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement parts

specified by Rosemount. Unauthorized parts and procedures can affect the product’s per-

formance, place the safe operation of your process at risk, and VOID YOUR WARRANTY.

Look-alike substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except

when maintenance is being performed by qualified persons, to prevent electrical shock

and personal injury.

If a Model 275 Universal HART

®

Communicator is used with this unit, the software within the

Model 275 may require modification. If a software modification is required, please contact

your local Fisher-Rosemount Service Group or National Response Center at 1-800-654-7768.

The information contained in this document is subject to change without notice.

HIGHLIGHTS OF CHANGES

Effective May, 1999 Rev. 4.0

Page Summary

Page P-6 Added new Quick Start Guide.

Page 3-1 Added Section 3, Setup.

Page 4-1 Removed calibration information from Operation section, and created

Section 4, Calibration.

Page 6-2 Expanded explanations of IFT status codes.

Section 6 Added new troubleshooting procedures.

Effective November, 2001 Rev. 4.1

Page Summary

Highlights Updated Highlights of Changes Appendix A page.

Appendix A Replaced Appendix A, Rev. 3.6 with Rev. 3.7.

Effective July, 2002 Rev. 4.2

Page Summary

Highlights Updated Highlights of Changes Appendix A page.

Page 4-1 Added reference to new Calibration Record sheet.

Page 4-9 Added new Calibration Record sheet.

Appendix A Replaced Appendix A, Rev. 3.7 with Rev. 3.8.

HIGHLIGHTS OF CHANGES

APPENDIX A

Effective May, 1996 Rev. 3

Page Summary

-- General. Updated appendix to reflect probe design changes.

Page A-13 Added “Extended temperature by-pass arrangements” to Figure A-13

(Sheet 3 of 3)

Effective June, 1996 Rev. 3.1

Page Summary

Page A-13 Updated part ordering information.

Effective August, 1996 Rev. 3.2

Page Summary

Page A-25 Updated cell replacement kit part numbers for the probe.

Effective October, 1996 Rev. 3.3

Page Summary

Page A-6 Added NOTE to Figure A-7.

Effective January, 1997 Rev. 3.4

Page Summary

Page A-1 Added warning to read new safety instructions.

Page A-12 Added protective covers and grounds warning.

Page A-16 Added protective covers and grounds warning.

Effective February, 1998 Rev. 3.5

Page Summary

Page A-18 Changed screw torque in paragraph A-11h.

Effective July, 1998 Rev. 3.6

Page Summary

-- Changed test gas to calibration gas and reference gas to reference

air throughout the appendix.

HIGHLIGHTS OF CHANGES (CONTINUED)

Effective November, 2001 Rev. 3.7

Page Summary

A-8 Added new cup type diffusion assembly description, paragraph A-6.e.

and diffusion assembly illustrations, Figure A-13 and A-14.

A-26 Added new cup type diffusion assembly part numbers 4851B89G04

and 4851B90G04 to replacement parts list. Deleted stainless steel

diffuser assembly from replacement parts list.

Effective July, 2002 Rev. 3.8

Page Summary

A-13 Added troubleshooting symptoms 5 and 6 to Table A-2.

HIGHLIGHTS OF CHANGES

APPENDIX B

Effective February, 1992 Rev. 2

Page Summary

Page B-1 Figure B-1. New HPS 3000 Optional Class 1, Division 1, Group B

(IP56) Explosion-Proof Enclosure added.

Page B-11 Figure and Index No. column added to Table B-2. Replacement Parts

for Heater Power Supply.

Effective January, 1995 Rev. 2.1

Page Summary

Page B-3 Updated Figure B-3, Heater Power Supply Block Diagram for IB

consistency.

Effective January, 1997 Rev. 2.2

Page Summary

Page B-1 Added warning to read new safety instructions.

Page B-3 Corrected Table B-1 specifications list.

Page B-4 Added protective covers and grounds warning.

Page B-8 Added protective covers and grounds warning.

Page B-11 Added expanded fuse description.

HIGHLIGHTS OF CHANGES

APPENDIX D

Effective June, 1994 Rev. 2

Page Summary

Page D-1

Page D-2

Page D-3

Page D-4

Page D-7

Page D-8

Page D-10

Page D-11

MPS outline drawing changed to show new MPS.

MPS interior view replaced with new MPS in Figure D-2.

"Optional" for check valve deleted in Figure D-3.

Drawing showing location of optional Z-Purge added as Figure D-4.

Power supply replacement procedures in paragraph D-7 changed to

reflect new design in the MPS. Solenoid valve replacement proce-

dures in paragraph D-8 changed to reflect new design in the MPS.

Old exploded view of MPS replaced with new MPS.

Paragraph D-11, Adding Probes to the new MPS, added.

Change part numbers for the power supply, solenoid valve, and test

gas flowmeter assembly. Add part numbers for reference gas flow-

meter assembly and all the parts in the probe adder kit.

Effective January, 1995 Rev. 2.1

Page Summary

Page D-1 Updated Figure D-1, MPS 3000 to include hinge.

Effective May, 1996 Rev. 2.2

Page Summary

Page D-11 Updated replacement parts list to reflect new part numbers.

Effective January, 1997 Rev. 2.3

Page Summary

Page D-1

Page D-2

Page D-5

Page D-7

Page D-11

Added warning to read new safety instructions.

Corrected Table D-1 Specifications listing, 1

st

entry.

Added protective covers and grounds warning.

Added protective covers and grounds warning, corrected item num-

ber errors in paragraph D-6.

Added expanded fuse descriptions.

Effective July, 1998 Rev. 2.4

Page Summary

--- Changed test gas to calibration gas and reference gas to reference

air throughout the appendix.

HIGHLIGHTS OF CHANGES

APPENDIX E

Effective May, 1996 Rev. 4

Page Summary

--- General. Updated text and illustrations to reflect new version of IFT.

Page E-4 Updated IFT display status codes and placed in priority sequence.

Effective June, 1996 Rev. 4.1

Page Summary

Page E-2 Updated specification table.

Effective October, 1996 Rev. 4.2

Page Summary

Page E-4 Added new status displays for password protection features.

Effective January, 1997 Rev. 4.3

Page Summary

Front matter Added "Safety instructions for the wiring and installation of this

apparatus.”

Page E-1 Added warning to read new safety instructions.

Page E-2 Deleted NOTE.

Page E-4 Added protective covers and grounds warning.

Page E-8 Added protective covers and grounds warning.

Page E-15 Added expanded fuse description.

Effective July, 1998 Rev. 4.4

Page Summary

--- Changed test gas to calibration gas throughout the appendix.

Effective June, 1999 Rev. 4.5

Page Summary

Page E-1 Changed “real time clock” to “timer”.

HIGHLIGHTS OF CHANGES

APPENDIX J

Effective April, 1995 Rev. 1

Page Summary

Page J-13 Added statement of reference to the return authorization number.

Effective June, 1995 Rev. 1.1

Page Summary

— Figure J-4. Updated figure to include “Status group” and “K3 eff” in

calculations.

Instruction Manual

IB-106-300NH Rev. 4.2

July 2002

Rosemount Analytical Inc. A Division of Emerson Process Management i

World Class 3000

TABLE OF CONTENTS

PREFACE........................................................................................................................P-1

Definitions........................................................................................................................P-1

Safety Instructions..........................................................................................................P-2

Glossary of Terms.........................................................................................................P-3

Quick Start Guide ..........................................................................................................P-6

1-0 DESCRIPTION AND SPECIFICATIONS...................................................................... 1-1

1-1 Component Checklist of Typical System (Package Contents).................................. 1-1

1-2 System Overview............................................................................................................ 1-2

2-0 INSTALLATION .............................................................................................................. 2-1

2-1 Oxygen Analyzer (Probe) Installation........................................................................... 2-1

2-2 Intelligent Field Transmitter (IFT) Installation.............................................................. 2-9

2-3 Heater Power Supply Installation ............................................................................... 2-14

2-4 Multiprobe Calibration Gas Sequencer Installation.................................................. 2-22

3-0 SETUP............................................................................................................................. 3-1

3-1 Overview.......................................................................................................................... 3-1

3-2 Configuring the Analog Output..................................................................................... 3-1

3-3 Setting Calibration Parameters....................................................................................... 3-1

3-4 Setting the O

2

Alarm Setpoints.................................................................................... 3-2

3-5 Configuring Efficiency Calculations............................................................................... 3-2

3-6 Configuring the Relay Outputs ..................................................................................... 3-2

4-0 CALIBRATION................................................................................................................ 4-1

4-1 Analog Output Calibration ............................................................................................. 4-1

4-2 System Calibration ......................................................................................................... 4-1

5-0 GENERAL USER INTERFACE (GUI) OPERATION.................................................. 5-1

5-1 Overview.......................................................................................................................... 5-1

5-2 Deluxe Version IFT Displays and Controls................................................................. 5-2

5-3 Help Key......................................................................................................................... 5-3

5-4 Status Line...................................................................................................................... 5-3

5-5 Quick Reference Chart.................................................................................................. 5-3

5-6 Main Menu...................................................................................................................... 5-3

5-7 Probe Data Sub-Menu................................................................................................... 5-3

5-8 Calibrate O

2

Sub-Menu.................................................................................................. 5-4

5-9 Setup Sub-Menu............................................................................................................. 5-4

6-0 TROUBLESHOOTING.................................................................................................... 6-1

6-1 Overview.......................................................................................................................... 6-1

6-2 Special Troubleshooting Notes...................................................................................... 6-1

6-3 System Troubleshooting................................................................................................. 6-1

6-4 Heater Problem ..............................................................................................................6-3

6-5 Cell Problem................................................................................................................... 6-5

6-6 IFT Problem.................................................................................................................... 6-7

6-7 MPS Problem .................................................................................................................6-8

6-8 Performance Problem (Process Response is Suspect)............................................. 6-9

Instruction Manual

IB-106-300NH Rev. 4.2

July 2002

ii Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

7-0 RETURN OF MATERIAL.............................................................................................. 7-1

8-0 APPENDICES ................................................................................................................. 8-1

Appendix A .....................................................................................................................A-1

Appendix B .....................................................................................................................B-1

Appendix D.....................................................................................................................D-1

Appendix E .....................................................................................................................E-1

Appendix J.......................................................................................................................J-1

9-0 INDEX.............................................................................................................................. 9-1

LIST OF ILLUSTRATIONS

Figure 1. Complete World Class 3000 System.....................................................................P-5

Figure 2. Wiring Layout for World Class 3000 System without HPS or MPS.......................P-8

Figure 1-1. Typical System Package ....................................................................................... 1-1

Figure 1-2. Typical System Installation .................................................................................... 1-5

Figure 1-3. World Class 3000 Typical Application with Intelligent Field Transmitters ............. 1-6

Figure 2-1. Probe Installation................................................................................................... 2-2

Figure 2-2. Orienting the Optional Vee Deflector..................................................................... 2-7

Figure 2-3. Air Set, Plant Air Connection................................................................................. 2-8

Figure 2-4. Outline of Intelligent Field Transmitter................................................................... 2-9

Figure 2-5. Power Supply Board Jumper Configuration ........................................................ 2-10

Figure 2-6. Signal Wire Routing............................................................................................. 2-11

Figure 2-7. IFT Power Supply Board Jumpers....................................................................... 2-12

Figure 2-8. Wiring Layout for IFT Systems without HPS ....................................................... 2-13

Figure 2-9. Microprocessor Board Jumper Configuration..................................................... 2-14

Figure 2-10. IFT Microprocessor Board ................................................................................... 2-15

Figure 2-11. Interconnect Board Jumper Configuration........................................................... 2-16

Figure 2-12. IFT Interconnect Board Output Connections....................................................... 2-16

Figure 2-13. Outline of Heater Power Supply .......................................................................... 2-17

Figure 2-14. Wiring Layout for Complete IFT 3000 System with HPS (Sheet 1of 2)............... 2-18

Figure 2-15. Heater Power Supply Wiring Connections .......................................................... 2-20

Figure 2-16. Jumper Selection Label....................................................................................... 2-21

Figure 2-17. Jumpers on HPS Mother Board........................................................................... 2-21

Figure 2-18. MPS Module ........................................................................................................2-22

Figure 2-19. MPS Gas Connections ........................................................................................ 2-23

Figure 2-20. MPS Probe Wiring ............................................................................................... 2-24

Figure 4-1. Typical Calibration Setup....................................................................................... 4-4

Figure 4-2. Portable Rosemount Oxygen Calibration Gas Kit ................................................. 4-5

Figure 4-3. Typical Portable Calibration Setup ........................................................................ 4-6

Figure 4-4. Typical Automatic Calibration System................................................................... 4-7

Figure 5-1. Deluxe Version IFT Displays and Controls............................................................ 5-2

Figure 5-2. Quick Reference Chart.......................................................................................... 5-5

Instruction Manual

IB-106-300NH Rev. 4.2

July 2002

Rosemount Analytical Inc. A Division of Emerson Process Management iii

World Class 3000

LIST OF TABLES

Table 4-1. Automatic Calibration Parameters......................................................................... 4-8

Table 5-1. Sample HELP Messages....................................................................................... 5-3

Table 5-2. MAIN menu............................................................................................................ 5-3

Table 5-3. PROBE DATA Sub-Menu...................................................................................... 5-4

Table 5-4. CALIBRATE O

2

Sub-Menu.................................................................................. 5-10

Table 5-5. SETUP Sub-Menu ............................................................................................... 5-12

Table 5-6. Efficiency Constants ............................................................................................ 5-14

Table 6-1. IFT Status Codes................................................................................................... 6-2

Table 6-2. Heater Troubleshooting......................................................................................... 6-3

Table 6-3. Cell Troubleshooting.............................................................................................. 6-5

Table 6-4. IFT Troubleshooting............................................................................................... 6-7

Table 6-5. MPS Troubleshooting ............................................................................................ 6-8

Table 6-6. Performance Problem Troubleshooting................................................................. 6-9

Instruction Manual

IB-106-300NH Rev. 4.2

July 2002

iv Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

IB-106-300NH Rev. 4.2

July 2002

Rosemount Analytical Inc. A Division of Emerson Process Management P-1

World Class 3000

NOTE

!

Only one probe can be calibrated at a time.

Probe calibrations must be scheduled

appropriately in multiple probe applications.

PREFACE

The purpose of this manual is to provide a comprehensive understanding of the World

Class 3000 Oxygen Analyzer components, functions, installation, and maintenance.

This manual is designed to provide information about the World Class 3000 Oxygen Ana-

lyzer. We recommend that you familiarize yourself with the Overview and Installation sec-

tions before installing your emissions monitor.

The overview presents the basic principles of the oxygen analyzer along with its perform-

ance characteristics and components. The remaining sections contain detailed proce-

dures and information necessary to install and service the oxygen analyzer.

DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this

publication.

Highlights an operation or maintenance

procedure, practice, condition, state-

ment, etc. If not strictly observed, could

result in injury, death, or long-term

health hazards of personnel.

Highlights an operation or maintenance

procedure, practice, condition, state-

ment, etc. If not strictly observed, could

result in damage to or destruction of

equipment, or loss of effectiveness.

NOTE

Highlights an essential operating procedure,

condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERS

The number in the lower right corner of each illustration in this publication is a manual illus-

tration number. It is not a part number, and is not related to the illustration in any technical

manner.

Instruction Manual

IB-106-300NH Rev. 4.2

July 2002

P-2 Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

IMPORTANT

SAFETY INSTRUCTIONS

FOR THE WIRING AND INSTALLATION

OF THIS APPARATUS

The following safety instructions apply specifically to all EU member states. They should

be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-

EU states should also comply with the following unless superseded by local or National

Standards.

1. Adequate earth connections should be made to all earthing points, internal and external,

where provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced.

The integrity of all earth terminals must be maintained at all times.

3. Mains supply cords should comply with the requirements of IEC227 or IEC245.

4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.

5. All cable glands used should be of such internal dimensions as to provide adequate cable

anchorage.

6. To ensure safe operation of this equipment, connection to the mains supply should only be

made through a circuit breaker which will disconnect all circuits carrying conductors during a

fault situation. The circuit breaker may also include a mechanically operated isolating switch.

If not, then another means of disconnecting the equipment from the supply must be provided

and clearly marked as such. Circuit breakers or switches must comply with a recognized

standard such as IEC947. All wiring must conform with any local standards.

7. Where equipment or covers are marked with the symbol to the right, hazard-

ous voltages are likely to be present beneath. These covers should only be

removed when power is removed from the equipment — and then only by

trained service personnel.

8. Where equipment or covers are marked with the symbol to the right, there is a

danger from hot surfaces beneath. These covers should only be removed by

trained service personnel when power is removed from the equipment. Cer-

tain surfaces may remain hot to the touch.

9. Where equipment or covers are marked with the symbol to the right, refer to

the Operator Manual for instructions.

10. All graphical symbols used in this product are from one or more of the follow-

ing standards: EN61010-1, IEC417, and ISO3864.

Instruction Manual

IB-106-300NH Rev. 4.2

July 2002

Rosemount Analytical Inc. A Division of Emerson Process Management P-3

World Class 3000

GLOSSARY OF TERMS

Abrasive Shield

An optional component that shields the probe from high velocity particulate entrained in the flue

gas stream.

Automatic Calibration

An automatic calibration can only be performed if the system is equipped with an MPS 3000 Mul-

tiprobe Calibration Gas Sequencer. Once a calibration is initiated by the operator or by the IFT on

a scheduled interval, all calibration actions are performed by the IFT. The MPS switched calibra-

tion gases under direction from the IFT.

Calibration

The process of measuring gases of a known concentration, and comparing that known concen-

tration to the actual values sensed by the instrument. After reading the calibration gases, the IFT

automatically adjusts the slope and constant values to ensure that the system is correctly reading

the process gas O

2

values.

Cold Junction Compensation

A method for compensating for the small voltage developed at the junction of the thermocouple

leads in the probe junction box.

Dead Band

The range through which a signal can be varied without initiating a response. In the IFT 3000,

dead band is used to prevent an oxygen signal near an alarm setpoint from cycling the alarm on

and off.

GUI

General User Interface. The GUI is the operator interface for the IFT 3000.

HART

A communications protocol using frequency shift keying (FSK) to transmit data on an analog out-

put line without affecting the analog output signal.

HPS

Heater Power Supply. An HPS should be used to provide power for the probe heater if the probe

is more than 150 ft (45 m) from the IFT.

IFT

Intelligent Field Transmitter.

In Situ

A method of analyzing process gases without removing them from the process stream.

MPS

Multiprobe Calibration Gas Sequencer. The MPS can provide automatic calibration gas se-

quencing for up to four probes.

Instruction Manual

IB-106-300NH Rev. 4.2

July 2002

P-4 Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Reference Air

Provides a known oxygen concentration to the reference side of the oxygen sensing cell.

Semiautomatic Calibration

Semiautomatic calibration is performed when the system does not include an MPS 3000 Multi-

probe Calibration Gas Sequencer. The IFT 3000 provides prompts to direct the user to switch

calibration gases when performing the calibration.

Thermocouple

An electrical device made of two dissimilar metals. A thermocouple develops a millivolt signal

proportional to its temperature.

Vee Deflector

Protects the optional ceramic diffusor from the process gases. The vee deflector must be posi-

tioned so it points toward the direction of the process gas flow. See Figure 2-2 for an illustration of

the vee deflector.

Instruction Manual

IB-106-300NH Rev. 4.2

July 2002

Rosemount Analytical Inc. A Division of Emerson Process Management P-5

World Class 3000

WHAT YOU NEED TO KNOW

BEFORE INSTALLING AND WIRING A ROSEMOUNT IFT 3000

INTELLIGENT FIELD TRANSMITTER

WITH WORLD CLASS 3000 PROBE

1. What is the line voltage being supplied to the IFT 3000?

Write the line voltage here __________

2. Use the following drawing, Figure 1, to identify which parts of the World Class 3000 system

are included in your system. Components in the shaded area are optional components.

WC PROBE 3000

STACK

THERMOCOUPLE

(OPTIONAL)

HPS 3000

(OPTIONAL)

LINE

VOLTAGE

LINE

VOLTAGE

IFT 3000

LINE

VOLTAGE

MPS 3000

(OPTIONAL)

CALIBRATION

GAS

BOTTLES

29850003

Figure 1. Complete World Class 3000 System

Instruction Manual

IB-106-300NH Rev. 4.2

July 2002

P-6 Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

QUICK START GUIDE

Use this Quick Start Guide if ...

1. You are using a World Class 3000 probe.

2. You are NOT using any optional components. Optional components are shown in the

shaded area in Figure 1.

3. You are familiar with the installation requirements for the IFT 3000 Intelligent Field Trans-

mitter and World Class 3000 probe.

4. You are familiar with the procedures for changing the jumpers located in the IFT 3000, as

described in Section 2, Installation.

If you cannot use the Quick Start Guide, turn to Section 2, Installation, in this Instruction

Bulletin.

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